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Flame Straightening Technique PDF
Flame Straightening Technique PDF
SK-198
.),
AUGUST 1969
‘.. .
... -
.
August 1969
Dear Sir:
$incerelv,
-,
,-
&
Rear Admiral, U. S. Coast Guard
Chairman, Ship Structure Committee
..— .—-
SSC-198
Summary Report
on
Project SR-185
to the
by
under
Department of the Navy
Naval Ship Engineering Center
Contract NOO024-68-C-5324
This document has been appoved fop public release and sale;
its distribution is unZ-imited.
August 1969
ABSTRACT
ii
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . .1
Nature of Distortion . . . . . . . . . . . . . . . . . . . .3
Flame-Straightening Techniques . . . . . . . . . . . . .6
Discussion . . . . . . . . . . . . . . . . . . . . . . . . .24
References . . . . . . . . . . . . . . . . . . . . . . .27
iii
SHIP STRUCTURE COMMITTEE
iv
introduction
(4)SECTION D-D “
The effects of these dimensional changes on a simple butt weld are shown in
Figure 2. Examples of distortion due to longitudirial shrinkage are shown in
Figure 3. The armunt and type of distortion that occurs in welchnents such as
those encountered in shipbuilding is much more complex than that shown in
ointa. In 1961 Kerr discussed the problem of distortion in
~h~;~ifi~$!~~) %rr indicated that a volumetric contraction of about 10
‘parcent occurs in the cooling of the weld zone in mild steel. The liqufd
w41d metal solidifies at about 2700 F. But it is highly plaatic at this tf=.
With decreasing temperature there Is a progreastve increase in sjkrength cd
the weld metal until the temperature reaches about 1650 F; during this period
the weld metal contracts and the stress leval increases. Below 1650 F, the
weld metal plasticity decreaaea and high stresses are present in the weld
=tal and surrounding .matal; these stresses produce distortion in the weldment.
-3-
Such standards must be rational and practical so that any harmful distortion
can be avoided while unharmful distortion is accepted to eliminate unnecessary
rework. In regard to structural reliability, studies are needed to determine
the adeqaacy of present tolerances. It is now possible to determine analyti-
cally the acceptable distortion of a member under given service conditions.
It is also possible to determine the maximum weld size that will produce ac-
ceptable distortion when welds are made with normal procedures. There is
considerable disagreement among shipbuilders and ship owners regarding the
amount of distortion that can lie tolerated from an economic viewpoint. Al-
though distortion may not affect a ship’s reliability, it may damage the ap-
pearance and thus reduce the ship’s worth. A study, in which classification
societies, government agencies, and ship owners are questioned, could be
used to establish acceptable standards. Finally, extremely close distortion
tolerances can result in extremely high fabrication cost. This is a factor
that must be carefully weighed whenever distortion standards are established.
Nature of Distortion
(c)BUCKLING DISTORTION
~UY
—x
x .— ~1111 +04’
‘x
+
1
Y
(a)
BUTT WELD
cOMPRESSION
Y
(b)DISTRIBUTION
OF UXALONGYY
.-f-xv-:’-<:URVE2
/’ REACTION
+
.%,
STRESS
x— —x
1 1 1
(c)
DISTRIBUTION
OF UYALONGXX
Fhme4traightening Techniques
UL.--_JlU4 ~
(14)
Fig. 5. Flame Straightening of Distortion in Ship Fabrication
Such is not the case with the high-strength, low-alloy steels that
have yield strengths in the order of 100,000 psi. These steels are furnished
in the quenched-and-tempered condition , and the temperatures and cooling rates
involved in flame stra~ghtening can have a serious effect on the microstructure
and mechanical properties of unwelded and welded plate. These steels acquire
their properties by water-quenching from a temperature of about 1600-1750 F
and tempertng at 1050-1275 F.* Depending on the composttton of the steel and
the heat treatment, the microstructure consists of (1) ferrite plus tempered
batnite or martensite, or (2) tempered bainite and martensite. The compo-
sition and mechanical properties of representative high-strength, low-alloy
steels are shown in Tables 1 and 2; most of hese alloys have been used or are
candidates for use in ship construction. ~36~ The transformation characteris-
tics of two of these alloys (Grades B and F in Table 1) are shown in Figurs 7;
these curves illustrate the variation in transformation behavior that must be
considered in flame straightening a particular high-strength steel. In Figure
7a a considerable period of time elapses before this steel starts to transform
h the pearlite transformation range of about 1300-1100 l?. This lapse Of
time insures that transformation to these undeshable high-temperature trans-
formation products will not occur unless the cooling rate is very S1OW.
Because of Its lower alloy content, the period of time that elapses before
transformation starts Ln the Grade B steel (Figure 7b) is much shorter than
that of the Grade F steel. In the Grade F steel , a moderately long per%od
of time elapses before transformation starts in the ferrite and upper bainite
temperature range of about 1100-950 F. AS a result, relatively thick plates
(up to at least 2 tnches thick) can be quenched wfth little or no transforma-
tion in this temperature range. This period of time is shorter for the Grade B
steel, and the thickness of plates that can be quenched to produce the desired
low-temperature bainitic or martensitic microstructure is l-1/4 inches or
less. The transformation products (soft ferrite, upper batnite, and high-
carbon martensite) that are produced in this temperature range have a degrading
effect on the notch toughness behavior of the steel even when tempered. The
curves indfcate that transformation to low-temperature bainitic structures
occurs in a relatively short time for both steels, and that transformation
to martenslte occurs at a relatively high temperature.
~cThe temperature from which the steel is quenched and the tempering tempera-
ture depend on the composition of the steel and the-required strength level.
-12-
Tim,:, sccon~z
1 For firebox quality DhosDhorua Ia 0035 rnax and fmlfur 0.640 max.
2 Thephosphorus and su~fw together nhoutd not exceed 0045.
~ L4ar be subntltutcd for part or all titanium conLent on a one-to on-basis.
Table 2. Properti~s cf Lnnuitudinal Tensile and Charpy V-!lotch Impact in Heat-Treated St
rablo~. .+ropcfiios dkngitudinal tonsilo and Charpy V-notch impact inh~at-troatid ~teels
Energy Aboo
Yield Point Tensile Minimum V-notch irnpac:t
or Strength Strength Elongation
(R### (R#X# in 2 in. Rcducticm
Thickness range percent in Arm, ~.
(aeeT:%%14) (in.) x lo~ x 10$ (rein) (rein) Longitudinal
NO. 2 1$)
Table 4. --Maximum Welding Heat Input in Joules/inch for Butt Joints in Grade F Steel
T~ble ~, -Maximum welding heat input in Joules/inch for butt i.aints in Grade F s?ecl
Amperes x volts x GO
Joules /inch of weld =
.%&d in inches Der MkIUte
h’OTE:Heat-input fimits for temwxaturts and thicknesses included; but not shown. in this table mw’ be
obtained by frttcrpolatmn.
25~0 higher heat inputs are alIowable for fillet we!d% such as T-hints.
Table 5. --Maximum Welding Heat Input in Joules/inch for Butt Joints in Grade B Steel
Tablw 5.*’! -Maximum welding heat input in Joule!/inch for bun ioi~t$ in Grade B steel
——
-19-
(58)
ABS-B and E-steel bars. The des<red amount of constraint was obtained
by machining a deep circumferential groove in prestrained and aged (330 F
for 2 hours) cylindrical bar specimens. The specimens were tested in tension
at -16 F and room temperature. The experimental results indicated a severe
reduction irIductil:ty for bars that were notched; the embrittling prestrain
decreased from about 0.75 for smooth bars (APS-B steel) to 0.05 for notched
bars. In 1968, Kabayashi and Mylonas discussed the effect of small dfs–
continuities (represented by small holes drilled in the bar stock before (59)
prestraining by compression) on khe prestrain required to produce brittleness.
The existence of these cliscontinuities reduced the amount of compressive pre-
strain causing brittleness to (1) one–third or one-fourth the amount needed
in soltd bars of E-steel, and (2) two-thirds to one-fourth the amount needed
in solid bars of ~S-B steel.
.—
-20-
120
~ 80
:==
a
.E
~ 40
E
“20 -..
‘ 200ml!ImzJ–jLtr--i
I
-.-.-=-
I Wflz
bars bent at 75” F i%%%
&5 0.20 0.25 0,30 0.35 0.40 0.45 0.50 0.55 0.60
Compressive prestroin Compressive pfestrain
Fig. 10. Reversed-Bend Tests of Unaged Fig. 11. Reversed-Bend Tests of Unaged
Bars cf E Steel Prestrained Bars of E Steel Prestrained
at Various Temperatures (64) at Various Temperatures (64)
c Mn Si P s
= =3 0=6 0025 0,022
,Test I
I [ i I 1
1 2 3 4
Distance from Center of Weld ,inches
WddingConditiom
Welding
Current, Welding Speed,
Test Weld ing M8thod Shape of Groove amperes —— in. /rein
1 Shielded metal -arc 60°V, O.35” deep 160 ,9.0(a)
2 Submerged -arc 60”V, O.16” deep 600 11.5
3 Submerged -arc 60”V, O. 12” deep 500 34.0
(a) For each pass.
A- .—
-23-
1600
---------
--*----
1 Ii
----------—-—----
I ! I
1400
4,
~
a“
1200
,----- ----
+
ABCED r
3
G
: 1000
e
Mz
800
600
The synthetic-specimen technique has been quite useful for studying the notch
toughness of the heat-affected zone in high-strength steels which undergo
complex transformation during welding.
Dfe.cussfon
The parameters that are most likely to affect base metal properties
during straightening are temperature, strafn, and various combinations of
temperature and strain. The results of the literature search are discussed
briefly on the bash of these parameters.
Table 6. Schedule for Stra ghtening Studies (Unwelded and Welded Test Specimens)
Mechanical Thermal
Plate Amount of Straightening Straightening
Code Type of Thickness, Distortion, Temperature, Temperature, Number of
Number Steel inch imch F 1? Test Plates
21 A441 1/2 2
22 Ditto Ditto 7/16 1200 2
11 11
23 Ditto RT 1
11 It 11
24 1300-1400 1
1! It It
24a 1100-1200 1
.—..—
-27-
REHIERENCES
(5) Kihara, H. and Masubuchi, K., Distortions and Residual Stresses Due to Weld-
=, Sampo Publishing Company, Tokyo, Japan, 1955.
(6) Kihara, H., Wanatabej M. Masubuchi, K., and Satoh, K., Research on
Welding Stress and Distortion,. The Society of Naval Architects Of
Japan, Tokyo, Tapan, 1959.
(7) Wanatabe, M. and Satoh, K., WeldinR Mechanics and Its Applications,
Asakura Publishing Company, Tokyo, Japan, 1965.
(9) HoIt, J., “Flame-Straightening: A Friend in Need, Part 1“, Welding Rngineer,
—40 (10), 44-46 (1955).
(l-l)Anonymous, “Flame Buckled this Steel ...and Flame Straightened It, Part I“,
Welding Engineer, ~ (2), 40-43 (1959).
(13) Ho~t, R. E., “Flame Straightening Basics”, Welding Engineer, —50 (9), 49-52
(1965).
(15) Pfeiffer, R., “The Flame Straightening of Sheet and Sheet Metal Structures”,
Mitteilungen der BEI?A,—14 (9), 1-7 (1963) (German).
-28-
(17) Guzevich, Yu. D., “Cold Straightening Beams DLstorted by Welding”, Automatic
Welding, ~ (7), 19-22 (1958) (Russian).
(18) Okara, V.G., 13arsht,V.D., Shatailo, D.V., Rozenman, Ya. Sh., and Tsalmzn,
L.B., “The Effect of Cold Straightening on the Mechanical Properties af
Welded Joints”, Automatic Welding, —18 (7), 32-35 (1965) (Russian).
(19) Steel Ship Construction Handbook, Nippon Kogyo Kuzai Renmei, Tokyo (1960).
(20) Stitt, J*R., “Distortion Control During Welding of Large Structures”, Paper
presented at the Society of Automotive Engineers and American Society of
Mechanical Engineers, Alr Transport and Space Meeting, New York, New York,
April 27, 1964, Paper 844 B.
(22) Crooker, T.W., and Harrison, H. L., “The Effects of Flame Cambering on the
Bending Strength of I-Beams”, Welding Journal, —44 (12], Research Supplement,
545-S to 548-s (1965).
(23) Higgins, T.R., Kaopman, K.H., and Grover, L., “Discussion on the Effects of
Flame Cambering on the Bending Strength of I-Beams”, Welding Journal, .45 (6)
Research Supplement, 284-s to 288-S (1966].
(24) Watanabe, M., and sa~~~, K., “On the Correction of Distortion in Walded
Thin Plate Structures”, Journal of Japan Welding Society, ~ , 194-202
(1951).
(26) Kihara, H., Nisida, M., and l?ujita, Y., “On the Residual Stresses Due
to SpaE Heating”, Document No. x-267-61, International Institute of
Welding, Commission X (1961).
(27) Maeda, T., and yada, T., “Fundamental Nature of Shrinkage Distortion
Due to Spot Heating on a Rectangular Plate”, Document NO x-327-63, In&sr-
national Institute of Welding, Commission X (1963).
(28) Maeda, T., and Yada, T., “Investigation of Shrinkage Due to Multiple
Spot Heating”, Document No. X-268-61, International Institute of welding,
Commission X (1961).
(2?) Canonico, D.A., Kottcamp, E.H., and Stout, R.D., “Accelerated Cooling of
Carbon Steels for Pressure Vessels”, Welding Journal, —40 (9) Research
Supplement, 400-s to 404-s (1961).
(30) Nippes, E. l?., “The Weld Heat-Affected Zone”, Welding Journal, ~ (1),
Research Supplement, 1-S to 18-S (1959).
-29-
(31) Masubuchi, K., Kusada, T., and Tamura, H. “Effect of Welding on the
Natch Sensitivity of Ship Steels”, Jnl. Japan Welding Society, —21 (1)
2-.9 (1957).
(33) Stout, R.D., and Doty, W.D., ‘TJeldability of Steel”, Welding Research
Council, American Welding Society (1953).
(34) Kihara, H., Masubuchi, K., and Tsmura, H., ‘kffect of Welding on the
Notch Sensitivity of Steel--Especially on the Embrittled Zone Due to
welding”, Brittle Fracture in Mild Steel and Their Welded JoLnts, The
Welding Research Committee of the Society of Naval Architects of Japan,
144-152 (1953).
(35) Nippes, E.F., and Savage, W. F., “Tests of Specimens Simulating Weld
Heat-Affected Zone, “welding Journal, 28 (12), Research Supplement, 599-S
to 616-s (1949).
(36) Welding Handbook, SectIon 4, American Welding Society, New York, N.Y.
Fifth Edition, (1966).
(37) Zick, L.P., ‘~esign of Welded Pressure Vessels Using Quenched and Tempered
Steels”, Welding Journalj 34
— (9), Research Supplement, 442-s to 448-S
(1955).
(39) Doty, W.D., and Grotke, G.E., “Some Observation on the Weldability Of
Quenched and Tempered High-Yield-Strength Alloy Steels”, Conference
Proceedings, U.S. Navy Bureau of Ships~ Washington, D.C., 34-67,
March 21 and 22, 1960.
(40) Aroold, P.C., “Problems Associated with the Welding of ‘T-1’ Material”,
Welding Journal, —36 (8), Research Supplement, 373-S to 381-S (1957).
(41) Rathbone, A.M., Connor, L.P., and Gross, J.H., ‘Weldability Of a High
Toughness Alloy Plate Steel with a Minimum Yield Strength of 140 Ksi”,
welding Journal, —43 (12), Research Supplement, 551-s to 563-s (1964).
(42) Lewis, W.J., Faulkner, G.E., Martin, D.C., and Rieppel, P.J., “Submerged
Arc Welding HY-80 Steel”, Welding Journal, ~ (6) Research Supplement,
266-s to 278-s (1960).
(43) Sibley, C.R., %eldfng of HY-80 Steel with the Gas-Shielded Metal Arc
process”, Welding Journal, 42, (5), Research Supplement, 219-S to 232-S
(1963).
(44) Doty, W.D., “Welding of Quenched and Tempered Steels”, Welding Journal,
—44 (7), Research Slipplement, 289-s to 309-S (1965).
(45) Notvest, K., “Effect of Thermal Cycles in Welding I)6Ac Steel”, Welding
Journal. 45 (4). Research Supplement. 173-S to 177-S (1966).
-30-
(47) Uchida, J. M., ‘Welding Evaluation of New High Strength Quench and Temper
Steels”, Welding Journal, —45 (l), Research Supplement, 31-S to 40-s (1966).
(48) k,per, C, R.,and Stout, R.D., ‘tieldability and Notch Toughness of Heat
Treated Carban Steel”, Welding Journal , ~ (9), Research Supplement,
385-s to 392-s (1968).
(50) Robinson, v.S., I?ense,A.W., and Stout, R.D., “The Creep-Rupture Properties
of Pressure Vessel Steels”, Welding Journal, —43 (12), Research Supplement.
531-S tO 540-S (1964),
(52) Hall, W. J., Kihara, H., Soete, W., and Wells, A.A., Brittle Fracture of
Welded Plate, Prentice-Hall, Inc., Englewood Cliffs, N.J. (1967).
(54) Mylonas, C., Drucker, D.C., and Isberg, L., “Brittle Fracture Initiation
Tests”, Welding Journal, ~ (l), Research Supplement, 9-S to 17-S (1957).
(55) Mylonas, C., “Prestrain, Size, and Residual Stresses in Static Brittle-
Fracture Initiation”, Welding Journal, —38 (10), Research Supplement,
414-s to 424-s (1959).
(56) Satoh, K., and Mylonas, C., “Reversed-Bend Tests of ABS-C Steel with
AS-Rolled and Machined Surfaces”, Ship Structure Committee Report No,
SSC-166 (April, 1965).
(57) Ludley, J.H., and Drucker, D.C. , “A Reversed-Bend Test to Study Ductile
to Brittle Transition”, Welding Journal, —39 (12), Research Supplement,
543-s to 546-S (1960).
(58) Mylonas, C., Kobayashi, S., Armenakas, A., “Exhaustion of Ductility under
Notch Constraint Following Uniform Prestraining”, Ship Structure Committee
Report No. SSC-173 (August, 1966).
(61) Terazawa, K., Otani, N., Yoshida, T., and Terai, K., ‘~ffect of High
Temperature Prestraintng on Retained Ducttlity of Steel,” International
Institute of Welding Document, No. IX-285-61 (1961).
-31-
(63) Korber, F., ELchinger, A., and Mailer, H., “Behavior of Prestrained Metals
during Tensile Loading”, Mitteilungen K. Wilhelm Institut Eisenforschung,
26, 71 (1943).
(65) Dvorak, J., “The Precompression Bending Test”, Welding Jaurnal, —45 (5)
Research Supplement, 235-240-s (1966).
(66) Terazawa, K., Otani, N., Vos!nida, T., and Terai, K., “Effects of High
Temperature on the Notch Toughness of Steel,” International Institute
of Welding,Document NO.IX-286-61 (1961).
(67) Masubuchi, K., Monroe, R.E,, and Martin, D.C., “Interpretative Repurt
on Weld-Metal Toughness”, Ship Structure Committee Report No. SSC-169
(Ju~Y, 1965) AIso, Welding Research Council Bulletin No. 111 (January,
1966) .
(68) Kihara, H., Masubuchi,K., and Tamura, H., “Effects of Welding on the
Notch Sensitivity of Steel - Especially on the Embrittled Zone Due
to Welding”, Brittle Fracture in Mild Steel and Their Welded Joints,
The Welding Research Committee of the Society of Naval Architects of Japan,
144-152 (1953).
(69.) Nlppes, E.F., Savage, W. l?., and Alllo, R.J., “Studies of the Weld
Heat-Affected Zone of T.-1Steel”, Welding Journal, ~ (12), Research
Supplement, 531-S to 540-S (1957).
(70) Nippes, E. F., and Emmerich, E.W., “Heat Affected Zone Study of an Eutectoid
Ultra-High Strength Steel’i,Welding Jouraal, —42 (12), Research Supplement,
547-S tO 556-s (1963).
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August 1969 31 70
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Clissificatiom
SHIP RESEARCH COMMITTEE
Maritime-Transportation Research Board
Division of Engineering
National Academy of Sciences-National Research Council
SSC-191, Plastic Flotiin the Local on Notches and C~acks in Fe-3Si Steel
Under Conditions Approaching Plane Strain by G. T. Hahn and A. R.
Rosenfield. November 1968. AD 680123.
1
SSC-197, An Investigation of the Utility of Compute~ Si ‘uZationto Predict
I
Ship structural Response in Waves by p. Kaplin T. p. Sarqent
and A. I. Raff. June 1969
I
. _.—- —.—-— .. ..... ..-.——.___ - -. _ ___ ._ __ L